Applying a forklift’s brakes inappropriately can cause the forklift to tip forward or lose its load. The workplace environment always needs to be considered.

Speed limits

Your hazard management process will determine the speed limits appropriate to your workplace. Consider the stability of the forklift under braking, its stopping distances and environmental factors.

Once you’ve determined the speed limits, these should be prominently signposted. Make sure signs are placed so that employees on forklifts can see them easily. Make sure speed limits are observed and enforced. Buy or hire forklifts with speed limiting devices or retro-fit them to your current forklifts.

Stopping distances 

You need to know stopping distances when you plan speed limits, forklift routes and your overall traffic management plan.

The following table shows the typical distance it takes for a 2.5 tonne forklift to stop once the employee has applied the brakes. This is in optimal conditions: travelling on a dry, even surface with good traction, driven by an alert employee not distracted by other activities.

For example, even at six kilometres an hour (i.e. walking pace) a forklift needs at least three metres to stop. 

The distance at which a forklift can stop is affected by:

 the speed at which it is travelling 

 the weight of its load 

 its mechanical and tyre condition 

 the road surface.

A laden forklift cannot use its maximum braking capacity, because the load will slide or fall from the tines, or the forklift will tip forwards.